In the vast expanse of the King Abdullah Economic City (KAEC), an industrial symphony is being conducted within the walls of Zahid Group’s Arabian Vehicles & Trucks Industry (AVI) facility. Here, the fusion of innovation and tradition marks a significant milestone in the region’s automotive industry.
UD Trucks, renowned for their medium and heavy-duty vehicles that cater to the robust demands of the transportation sector, are assembled with unparalleled excellence. This facility is a beacon of progress, being the only one in the world to assemble Volvo Trucks, Renault Trucks, and UD Trucks on a single production line. This extraordinary feat exemplifies Zahid Tractor, AVI, and Zahid Group’s dedication to fostering career opportunities and propelling the professional growth of Saudi Arabian nationals.
During a recent site visit, guided by AVI’s General Manager, Lee Morphew, an in-depth exploration of the facility’s operations provided insight into these trucks’ integral role and assembly. He initiated the journey with an enlightening introduction, pointing towards the main assembly line, which set the stage for an immersive dive into the precision, productivity, and innovation that defines AVI’s operations. He also noted that this dedication is not confined to the assembly alone; it encompasses a broader culture of continuous improvement and adaptability, crucial as the facility integrates new guidelines from UD Japan with its established methodologies.
AVI keeps the line moving
“From a logistics perspective, let me briefly explain how the AVI assembly line operates. We have a dual-feed system for supplying materials, ensuring that our production line is continuously stocked and doesn’t run low on supplies. Instead of supplying materials for each truck individually, we do so in batches. When we deplete our initial supply, we replenish it from our inventory stored along the wall. This method is efficient and time-saving, particularly when we switch between manufacturing different brands like Volvo or Renault. As soon as one batch of trucks is completed, we quickly transition to the next, maintaining a seamless flow of production.
“Regarding the interchangeability of parts, our models, including the Questor, which is based on a Volvo design, currently share similarities, allowing for some interchangeability. This efficiency is further supported by our suppliers for Volvo, Renault, or UD, who pre-package and label materials specifically for our assembly needs. When an order is placed, the required materials are dispatched to us, pre-sorted and labelled for direct use on the assembly line. This system ensures that logistics are tightly managed and that materials are always ready and correctly allocated for each truck’s assembly.”
He added that once the shelves are depleted, the products are replaced from the yard.
Morphew pointed out the chassis, the skeleton of the truck, marked with engraved numbers and pre-drilled holes, is the first to start being assembled. “This is the start, and that’s what we call stage zero at the moment,” he said, emphasising the foundation upon which each truck is built.
The cleanliness of the components and the organised chaos of parts awaiting assembly highlights the orchestrated effort that AVI makes to maintain quality and efficiency. “We have to wash it for the first time,” he said, underscoring the importance of starting with a clean slate to ensure the final product meets the industry’s rigorous standards and the global market’s expectations.
He continued, “Each week, we assess our needs based on the production schedule. For each truck we assemble, it involves integrating roughly 10,000 parts – that’s around 10,000 individual components including pipes, harnesses, crossmembers, and various screws – some riveted, others requiring different methods of attachment.”
He noted that while this might sound overwhelming, many of these components are part of pre-assembled sets, which streamline the assembly process. “If we consider each unique part number, excluding duplicates, the count narrows down to between 800 to 1,200 distinct part numbers. This level of detail underscores the complexity and precision involved in truck manufacturing,” Morphew added.
AVI committed to global performance system
At the core of AVI’s success is a commitment to a global performance system, ensuring that each employee operates within a specific level and standard. “It’s not just about assembling parts; it’s about maintaining a rhythm, a standard that elevates our work beyond mere assembly. It ensures that we are not just working; we are creating something exceptional,” he explained.
The facility operates with a precision that belies the complexity of its task. Contrary to the industry norm, the plant thrives on a single eight-hour shift, underscoring the efficiency and ergonomic focus that allows them to potentially exceed their capacity without resorting to overtime.
“Our facility is designed for 4,000 plus units – the highest we have had is 3600 last year – but with the dedication and efficiency of our team, we believe we can reach 5,000 units within the same framework,” Morphew stated, showcasing the ambitious yet grounded vision that drives the AVI team forward.
Pre-assembly areas and a mainline consisting of all the stations ensure that every component, screw, and harness is meticulously organised and synchronised, guaranteeing a seamless assembly process. “Every part has its place, synchronised by part number and chassis number, ensuring that when a truck leaves our facility, it’s not just built, it’s crafted,” he further elaborated.
“To simplify our assembly process, we categorise parts based on their placement and assembly requirements. Components that attach directly to the chassis are kept on the main assembly line. For parts that need to be assembled into larger units, like crossmembers that require the addition of harnesses and connections, we use a pre-assembly area. This approach prevents the main line from becoming overly congested and reduces the need for additional manpower.
“In essence, smaller parts are assembled into bigger ones in the pre-assembly before being integrated into the final product on the main line. This system ensures that all materials are meticulously synchronised according to the specific needs of each chassis.
“Regarding the organisation of these components, for example, a crossmember designated for a particular chassis is prepared and aligned around different stations, but are synchronised by part number and chassis number. To manage this complexity, we hold meetings to review our progress and ensure everything is on track.”
Integral to this orchestration of parts and people is a series of daily meetings that cascade from teams to management, ensuring alignment and swift resolution of any issues.
Co-ordination is key
“Every morning at 7:30, our teams gather to discuss the day’s targets, address any quality issues, and share feedback from other departments, setting the stage with a daily production plan that everyone receives. By 8:00, we have a cross-functional meeting involving team leaders and supervisors across all departments, including logistics, to ensure synchronisation with the day’s tasks. It’s crucial; no one is allowed to be late. Following this, at 8:30, management convenes to review and make decisions based on the earlier discussions,” Morphew explained, highlighting the no-compromise approach to punctuality and precision that permeates the facility’s culture.
“The trucks’ assembly worldwide is almost similar,” Morphew continued. “But here, we diverge from the norm. Unlike Sweden’s model, which employs more stations and people for speed, our strength lies in our versatility. Each employee is proficient in multiple stations, a testament to the high competence we cultivate.”
This multifaceted skill set also gives them a strategic advantage, as he reveals how the Saudi facility was selected to support Australia. As we delve deeper into the facility, the conversation shifts to logistics, showing the meticulous planning behind each assembly line.
“Here, logistics is like an orchestrated symphony. From the unpacking area to the assembly instructions, every part number, every batch is accounted for, ensuring that we maintain our pace without compromising on quality,” Morphew described, highlighting the seamless transition between brands and variants the facility has mastered.
But it’s not just the logistics and craftsmanship that define AVI’s facility; it’s the adaptability and attention to human factors. “When we introduced women to the assembly line in 2020, we didn’t just add more hands; we rethought our workspace. Adjustable tables, ergonomic chairs—every change aimed at creating an inclusive, productive environment for all,” he shared, reflecting on the transformative approach to workplace design. As we move through the facility, it’s clear that precision and quality are at the forefront of everything UD Trucks does.
Guiding us past rows of gleaming trucks, their cabs painted in the stark white that dominates the region’s preferences, Morphew explained, “While most of our cabs come painted in white, reflecting the common choice in the kingdom, our flexibility allows for customisation. If a customer requests a special colour, our marketing division is equipped with a specific workshop to accommodate that, ensuring the truck is delivered as desired.”
Meticulous about quality
The tour ventures into the heart of the plant’s quality assurance processes, the quality audit room. Here, Morphew illustrated the meticulous care with which each truck is examined. “A truck is selected at random and spent a day on as a sample. The results are then shared with the team to ensure every vehicle meets our stringent quality standards. With check cards that are signed by employees and quality inspectors at three stations and a final comprehensive review at the final stage, we leave no stone unturned.”
“After the vehicle’s electrical connections are verified, it undergoes a 15-kilometre test drive to ensure everything functions correctly. Following the test, the vehicle is inspected again via computer. If everything checks out, we will sign it off for delivery. Before dispatch, vehicles ready for delivery undergo a final quality inspection, where we randomly select units to ensure consistency and reliability for our customers.”
The conversation shifts to the assembly process, where Morphew highlights AVI’s commitment to craftsmanship. “Most of our assembly is done by hand,” he notes, emphasising the importance of flexibility and customisation in their operation. “Unlike cars, trucks undergo a lot of customisation. Today, a truck might be a tipper; tomorrow, it may need to be converted into a crane. Our method allows for this adaptability.”
Almost concluding the factory tour, Morphew shared his personal aspirations and the broader social engagements of UD Trucks, mentioning initiatives related to gender equality and CSR partnerships. It’s a reminder of the company’s commitment not just to quality truck manufacturing but also to its role in supporting diverse communities and interests.
The site visit to UD Trucks was more than just a tour; it was an insightful journey into the dedication and intricacies behind the vehicles that form the backbone of our modern economy. Under Morphew’s guidance, we left with a deeper appreciation for AVI’s meticulous work that ensures these “silent workhorses” are ready to take on the road’s challenges, embodying the robustness, efficiency, and adaptability essential for the long hauls ahead.